Thermoplastics and Composites for the Oil & Gas Industry

06/2017

Röchling Competence in Plastics

Contents

Page

Röchling Group .............................................. 2 Real hardness test ........................................ 3 Materials for topside applications ............ 4–5

The Röchling Group, which is headquartered in Mannheim, includes a large number of locations in countries all over the world. With a workforce of several thousand employees, we manufacture our products in close proximity to our customers and markets. Our three company divisions, Industrial, Automotive and Medical, generate billions in sales every year on the European, American and Asian continents.

Materials for transportation & pipelines ... 6–7 Materials for subsea applications ............. 8–9 Materials for downhole applications ..... 10–11

Röchling Industrial

Unique range ......................................... 12–13 Advantages of our thermoplastics................ 14 and composites Quality and Innovation ................................. 15

The Industrial division has a broad product range offering thermoplastics and composite materials as well as high-performance plastics. Customers receive these products in the form of semi-finished products such as sheets, rods, tubes, flat bars, profiles and finished castings or as precision, machined and assembled components.

Your ideas become high quality components This one-of-a-kind, international network of companies provides you with the material expertise of one of the most innovative manufacturers of semi-finished plastic parts, machined components and composites as well as outstanding industry know-how and machinery that is unparalleled in the world. You benefit from the synergies of the global locations of the Division. We look forward to meeting your most challenging needs.

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Oil & Gas – real hardness test

Materials for the most demanding environments

Reliable and durable

Machined components and semi-finished products

Oil & Gas exploration occurs in some of the most demanding environments on the planet, with demands on materials including:

When working miles from land, equipment must work safely every time. Materials from Röchling offer the highest levels of quality and our internal labs can supply supporting documentation (such as 3.1 certificates according to EN 10204).

Röchling offers one of the widest ranges of thermoplastic and composite materials available. With its global presence, we are able to quickly meet your requirements anywhere in the world.

•Corrosive seawater •Abrasive (sand/rocks) conditions •Exposure to sour gas and completion fluids •Fluctuating weather conditions including, high (desert) and low (arctic) temperature environments Röchling offer materials which provide solutions to these and more environmental challenges. Speak to us to find out more!

Röchling materials: •Are naturally corrosion resistant •Offer extreme wear resistance •Have excellent chemical resistance •Exhibit thermal stability in low and high temperature environments •Are weather resistant (UV)

Our semi-finished materials and machined components, to customers drawings, will keep key equipment operating under the extreme and demanding conditions found during Oil & Gas exploration and production.

Typical materials offered by Röchling for use in the Oil & Gas Industry Composites

Thermoplastics •SUSTAPEEK (PEEK) •SUSTAPVDF (PVDF) •SUSTAMID (PA) •SUSTARIN (POM) •SUSTADUR PET (PET) •SUSTAKON (PK) •SUSTATRON PPS (PPS) •PTFE

•Polystone® P (PP) •Polystone® M (UHMW-PE) •Polystone® D (HMW-PE)

•Durostone® – glass-fibre reinforced polyester or epoxy laminates •Lignostone® cryogenic, Lignostone® HII/2 30, Lignostone® LII/2 – laminated densified wood •Durolight, Durolight S, Durolight S1, Durolight S2, Durolight S3 – thermally insulating pipe supports from -196 °C to +200 °C

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Proven materials for topside applications

Oil & Gas production in offshore environments puts materials under some of the most demanding conditions found on the planet. These often include intense UV radiation, corrosive salt water and abrasive sand (winds), not to mention the extreme thermal conditions found in both arctic and tropical environments. Yet all environments require the safe and efficient operation of equipment every time. Typical applications include: • Catwalk shuttle components • Cable clamps • Structural supports • Grating, fencing • Launch and recover system (LARS) components • Cable lay equipment (sheaves/sheave segments) • Diablo rollers • Tank supports

Product examples

4 | Röchling Industrial

Tank supports and pipe supports

Approved quality

Lignostone® cryogenic is a laminated densified wood which offers exceptional properties, making it ideal for use as tank supports (picture), chocks, fixed blocks and sliding blocks in LNG transport vessels as well as pipe supports. Low thermal conductivity, low weight, a low coefficient of friction and an ability to withstand high mechanical loadings are some of the advantageous properties that Lignostone® cryogenic offers. Beside this the material is suitable to operate in environments with temperatures from -196 °C to +90 °C (-320 °F to 194 °F).

Lignostone® cryogenic is approved by LR, BV, NKK, GL/DNV, IHI and JMU.

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Proven materials for topside applications

Winch drum shell

Typical material:

Installation & retrieval of equipment from subsea environments leads to high demands on cables. To help mitigate this Röchling`s range of SUSTAMID materials can lead to an increase in cable life. This is due to the low coefficient of friction and excellent wear resistance of SUSTAMID materials, further enhanced by the excellent impact resistance and significant weight reduction compared to steel.

SUSTAMID 6G (PA 6G), SUSTAMID 6G MO (PA 6G + lubricant), SUSTAMID 6G ESD 60 / 90 (PA 6G – for charge critical environment)

Bend restrictor/spacer

Typical material:

Bend restrictors encase and protect pipelines, umbilical’s and cables during operation; as excess bending could lead to failure of the cable/pipe. SUSTAMID 6G can be readily coloured and cast to a size to offer an economical solution with long life and high mechanical properties.

SUSTAMID 6G (PA 6G)

Slide pads/skid pads

Typical material:

Movement of production equipment around a rig, ship or the sea floor can lead to damage by abrasion and contamination. Polymers offer significant advantages (low friction, high wear, impact resistant and self-lubricating) for all sliding applications.

LubX®, SUSTARIN C (POM-C), SUSTADUR PET(PET), SUSTAMID 6G (PA 6G), SUSTATRON PPS (PPS), SUSTAPEEK (PEEK), SUSTAPEEK GLD 140 (PEEK)

Fenders

Typical material:

Mounted on fender systems, sliding sheets made of our special material Polystone® FM protect quay bulkheads and ships during mooring and harbour manoeuvring and during idle periods. The ready-to-mount sheets are characterized by high abrasion and wear resistance and are resistant to corrosion, UV radiation and weathering.

Polystone® FM

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Proven materials for transportation and pipelines

Transportation of hydrocarbons has its own challenges. Röchling materials have been proven in the most demanding applications from cryogenic to high temperature as well as NORSOK M-710 approved grades. Typical applications include: • • • • • •

Pipe-in-pipe centralisers Pipe supports Thermal insulation Corrosion protection Fasteners Tube guides

Product examples

6 | Röchling Industrial

Durostone® fasteners

Typical material:

Oxidation of steel fasteners leads to the need for regular replacement or the use of costly titanium or super duplex grades. An alternative to these are Durostone® fasteners, which are not affected by oxidative degradation. Durostone® fasteners offer high strength and are naturally corrosion resistant, as well as highly weather and chemical resistant, but weight ~75% less than an equivalent sized steel fastener.

Durostone® fasteners (glass fibre composite), SUSTAPEEK CF30 (carbon fibre reinforced) fasteners also possible

Tube Guide / Pipe supports

Typical material:

Pipe supports and tube guides made of our thermoplastic materials like SUSTARIN C, Polystone® M, Polystone® G and SUSTAPEEK offer you a number of advantages over traditional metal alternatives. With thermoplastic materials being naturally corrosion resistant, having low coefficients of friction and a ductile nature being of benefit when clamped around pipelines/ umbilical’s. These advantages combine to increase the ease of operation of the equipment.

Polystone® M (UHMW-PE), Polystone® G (HD-PE), SUSTARIN C (POM-C), SUSTAPEEK (PEEK)

Proven materials for transportation & pipelines

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Pipe-in-pipe centralisers

Typical material:

As well as offering a standard PiP centraliser, Röchling having listened to the demands of the industry and have developed a proprietary centraliser to reduce friction during pull-through on the flow line.

SUSTAMID 6G (PA 6G), High Friction Centraliser, Design (HFE Centraliser)

Ball valve seats

Typical material:

Flow lines and production equipment all depend on seals and valve seats to operate. Because of our broad material range, we can offer the optimum material depending on the chemical, thermal and mechanical requirements.

NORSOK M-710 tested SUSTAPEEK (PEEK), NORSOK M-710 tested PTFE and filled PTFE, SUSTAMID 6G (PA 6G), SUSTATRON PPS (PPS), SUSTAKON (PK), Polystone® M (UHMW-PE)

Insulating load bearing pipe supports

Typical material:

Durolight, a fibre reinforced insulating composite was developed to meet the thermal and mechanical requirements of load bearing supports in LNG applications (from -196 °C to +200 °C) making it an excellent choice for pipeline insulation and as thermal breaks. (Picture printed with kind permission of Pipe Support Ltd.© 2003)

Durolight, Durolight S, Durolight S1, Durolight S2, Durolight S3

Cryogenic pipe supports

Typical material:

Lignostone® HII/2 30 is a laminated densified wood which offers exceptional properties, making it ideal for use as load bearing cryogenic supports. Low thermal conductivity, low weight, a low coefficient of friction and an ability to withstand high mechanical loadings are some of the advantageous properties of Lignostone® cryogenic has. Beside this the material is suitable for operation in environments with temperatures from -196 °C to +90 °C (-320 °F to 194 °F).

Lignostone® HII/2 30

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Proven materials for subsea applications

Plastics in subsea environments offer many efficiency and economic advantages over traditional materials by being naturally corrosion resitant and weighing up to 50% less than aluminium. Typical applications include: • • • • • •

Pipeline-systems ROV components Subsea connectors Support structures Signage Tree and wellhead equipment

Product examples

8 | Röchling Industrial

Durostone® fasteners

Typical material:

In offshore environments, oxidation of fasteners can rapidly happen, unless costly titanium or super duplex grades are used. An alternative to these are our Durostone® fasteners, which are not affected by oxidative degradation like steel. Durostone® fasteners offer high strength and are naturally corrosion resistant, as well as highly weather and chemical resistant, but also only weight approximately 75% less than an equivalent sized steel fastener.

Durostone® fasteners (glass fibre composite)

Subsea tree caps

Typical material:

Protection of the wellhead using a polymer cap offers an efficient, naturally corrosion resistant and insulating solution to traditional metallic solutions.

SUSTARIN C (POM-C), SUSTAPVDF (PVDF), SUSTAPEEK (PEEK)

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Proven materials for subsea applications

Subsea structure – pipe flange

Typical material:

Compared to metallic flanges polymer flanges (such as SUSTAPEEK) can lead to significant weight reduction, especially when combined with polymer flowlines. They also offer excellent chemical resistance and have a broad temperature range.

NORSOK M-710 approved SUSTAPEEK (PEEK), Durostone®

Sensor body housings

Typical material:

A radio transparent housing made from polymers to protect the delicate electronics from corrosive sea water or sour gas environments can be achieved with Röchling materials.

SUSTARIN C (POM-C), SUSTAPEI (PEI), SUSTASON (PPSU, PES, PSU), SUSTAPEEK (PEEK)

High voltage electrical connectors

Typical material:

Polymer electrical and communication connectors are the optimum solution with good electrical resistance, low moisture absorption, high dimensional stability and impact resistance for Dry-Mate and Wet-Met systems.

SUSTAPEEK (PEEK), SUSTAPEI (PEI), SUSTASON (PSU), SUSTARIN C (POM-C)

ROV Components

Typical material:

Remote Offshore Vehicles (ROVs) are continuous being designed to operate in ever increasing depths. To aid this, we supply numerous corrosion resistant, key components used to assemble an ROV. PP & PE are used for the frames to replace steel & aluminum. POM, PA and PEEK are used for mechanical components for the robot arm and are used for the light housings. All Röchling materials help to reduce weight and maintenance work of the vehicles and extend its lifetime as well.

Polystone® D (HMW-PE), Polystone® P (PP), SUSTAMID 6G (PA 6G), SUSTARIN C (POM-C), SUSTAPEEK (PEEK), Durostone® (glass fibre composite)

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Proven materials for downhole applications

Downhole environments are some of the most demanding involved with oil & gas production with a cocktail of chemicals such as hydrocarbons, H2S, production fluids, lubricants and grease in combination with high temperatures (>120 °C) present. Depending on the exact environmental conditions we can advise you on the suitability of engineering plastics or high temperature materials for your application. Typical applications include: • • • •

Seal and valve seats Back-up rings Frac balls Centralisers

Product examples

10 | Röchling Industrial

Anti-extrusion (back-up) rings

Typical material:

When PTFE seals are used, a back-up ring is often required to ensure the PTFE seal is kept in place. Röchling offer SUSTAPEEK and SUSTATRON PPS for these applications, with fibre filled grades possible for greater load environments. Both SUSTAPEEK and SUSTATRON PPS offer high maximum usage temperatures, impressive mechanical properties and excellent chemical resistance to typical conditions found in downhole environments. Röchling offer one of the widest range of sizes of extruded PEEK tubes available direct from stock, which enables efficient production.

SUSTAPEEK (PEEK), SUSTATRON PPS (PPS)

Proven materials for downhole applications

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Seals & back-up rings

Typical material:

NORSOK M-710 tested grades of PEEK and PTFE provide confidence under the most demanding sour gas conditions with nylons and PE also available for lower temperature environments.

NORSOK M-710 tested SUSTAPEEK (PEEK) and PTFE, SUSTATRON PPS (PPS), SUSTAMID 6G (PA 6G), SUSTAMID 6G OL (PA 6G +oil), Polystone® M (UHMW-PE)

Frac balls

Typical material:

During hydraulic fracking, frac balls are subjected to high pressures to ensure the release of hydrocarbon reserves. For these applications, SUSTAPEEK offers the optimum combination of chemical resistance to fracking fluids, mechanical properties and high thermal stability. Beside this we offer you frac balls made of our Durostone® glass fibre composite material.

SUSTAPEEK (PEEK), Durostone® (glass fibre composite)

Riser centralisers

Typical material:

Ensuring the position of the drilling riser from the casing is key during drilling. With Röchlings range of polymers, low coefficient riser centralisers or slide pads offer high impact and abrasion resistance as well as being resistant to oils and grease making them efficient solutions for all environments.

NORSOK M-710 tested SUSTAPEEK (PEEK), SUSTAPVDF (PVDF), SUSTAMID 6G (PA 6G), SUSTAMID 6G OL (PA 6G +oil), Polystone® M (UHMW-PE)

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Competence in materials Composite solutions for Oil & Gas

Important characteristics of plastics • Corrosion resistance (sea water) • UV resistant • Lightweight • High mechanical strength • Excellent chemical resistance • Naturally electrical & thermal insulators • High impact resistance

Röchling offers you a unique range! For more than 100 years, Röchling has specialised in the processing of plastics. Today the product range is comprised of more than 150 different types of plastics – from Standard Plastics to High Performance Plastics that withstand high operating temperatures, loads, and corrosive chemicals. The wide variety of modifications and special developments is also unparalleled worldwide. You can benefit from this material range, the knowledge of our excellently trained plastics experts, our technological leadership, own training centres and internal materials laboratories.

Thermoplastics

High-performance plastics

Engineering plastics

Industrial plastics

150 °C 302 °F

SUSTAPEI SUSTASON PPSU SUSTASON PES SUSTASON PSU

SUSTAPPE SUSTADUR PBT SUSTANAT PC SUSTADUR PET SUSTARIN (POM) SUSTAVACU (PA 6 GF) SUSTAGLIDE SUSTAMID (PA, PA 66, PA 6 G) SUSTAKON (PK) Matrox®

100 °C 212 °F

TroBloc® Astrawood® Cool

SUSTAABS MAYWO (ABS) MAYWO (PS) Formaterm® Rimito® Trovidur® (PVC) Trovicel® (PVC)

amorphous All Röchling materials are available for machining.

12 I Röchling Industrial

SUSTAPEEK PTFE SUSTATRON PPS Vitrite® HTS SUSTAECTFE SUSTAPVDF Polystone® PVDF

Polystone® P (PP) Polystone® M (PE 1000) Polystone® D (PE 500) Polystone® G (PE 300) Polystone® E (PE-LD)

semi-crystalline

Foamlite® LubX® Polystone® Play-Tec® Polystone® Marine-Tec Polystone® SafeTec

Competence in materials Composite solutions for Oil & Gas

Composite materials

Reinforcement • Glass or carbon fibres • Roving, mat, fleece, woven or non-crimp fabric

Resin • Unsaturated polyester (UP) • Vinylester (VE) • Epoxy (EP) • Polyurethane (PUR)

Laminated densified wood – beech veneers (Fagus sylvatica) with phenolic resin

Products Composite Fasteners •Naturally corrosion resistant materials as alternative to costly super duplex and titanium components •Standard sizes M8 to M30 threaded rods, further sizes possible •Highly UV and weather resistant •High mechanical strength and 30% lighter weight than aluminium

Thermal Insulation

Compression Moulded Composite Components

Pultruded Composite Profiles

• Durolight and Lignostone grades suitable for continuous use down to -196 °C (-320 °F ) •Glastherm grades suitable for environments up to +500 °C (932 °F) •Very low thermal conductivity •Weather resistant

•Production of pressed parts up to 2200 mm x 1600 mm x 1200 mm •Smooth surface of complex shapes •Good mechanical strength and naturally self-extinguishing

•Naturally corrosion resistant materials to replace structural metal components •High strength (E-Modulus’ up to 110 GPa) and low weight (1.5-2.1 g/cm3) •Weather resistant •Large range of sizes and shapes possible including: I/H-beam, box section, angle, channels, square hollow profiles •Width: max. 1000 mm •Height: max. 600 mm

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Advantages of our thermoplastics and composites

Thermoplastic and composites from Röchling offer the highest level of reliability and durability as well as having clear advantages over conventional materials.

Chemical & corrosion resistance

Economical advantages

• Excellent corrosion resistance (seawater) • Excellent resistance to sweet and sour gas environments • NORSOK M-710 tested grades

• Eliminates the need for cathodic protection • Reduces maintenance intervals • Increases part lifetimes

Low weight

Cryogenic to high temperature

• Very low density materials • Engineering & high performance plastics 1/7th weight of steel • PE/PP grades naturally buoyant • Composites 30% lighter than aluminium

• Polymeric materials can operate in temperatures from -196 °C to + 500 °C!

High mechanical properties

Tribological properties

• High stiffness • Good impact resistance • High dimensional stability

• Excellent wear resistance • Low co-efficent of friction • Self-lubricating grades available

Flame retardant

Charge critical

• • • •

• Naturally electrically insulating • Grades suitable for use in ATEX environments available • Naturally thermally insulating • Zone I/IIA suitable and tested material (according to ISO 80079-36)

UL 94 (V0) High Limiting Oxygen Index Asbestos free Halogen free

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Quality and Innovation lude: ards inc d n a t s al h w materi Our hig y, from ra

aceabilit t nt aterial tr • Full m hined componen able cost efficie to mac boratories en to al la ting • Intern ct material tes ates according and exa 2.2, 3.1 certific , n (e.g. 2.1 ) ied out o 4 0 2 ecks carr ction process 0 h c ty EN 1 li a e produ uous qu • Contin ls throughout th on machined a ri rt o rep s mate spection in M M •C ents compon

Competitive advantages through innovation Our quality management system is regularly inspected in audits in accordance with DIN EN ISO 9001:2008 ff. and its compliance ensured. Moreover, our products undergo ongoing controls in all phases of the production process. Includes Quality management systems regularly checked and accredited to: • ISO 9001 • ISO 13485 • ISO 14001 • AS9100 • FPAL Registered At Röchling, our top priority is innovation. This allows us to present the market with product developments that provide our customers with competitive advantages. We develop new products and manufacturing processes to fit the specific problem definitions of our customers in our excellently outfitted materials laboratory, and in close cooperation with suppliers, scientists and institutes. We actively engage in serving the industries through our collaboration with numerous advisory boards and committees, and thus, help define the quality standards of the future. Our internal labs allow us to continuously check the quality of our material as well as provide certification as per your requirements (e.g. 2.1, 2.2, 3.1 certificates according to EN 10204).

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EUROPE GREAT BRITAIN Röchling Engineering Plastics (UK) Ltd. Waterwells Drive, Quedgeley, Gloucester GL2 2AA [email protected] www.roechling-plastics.co.uk Tel. +44 1452 72-7900 Röchling Fibracon Ltd. Bowden Hey Road Chapel-en-le-Frith, High Peak Derbyshire SK23 0QZ www.roechling-fibracon.co.uk Tel. +44 (0)1298 811 800

Röchling Engineering Plastics SE & Co. KG Röchlingstr. 1, 49733 Haren [email protected] www.roechling.com Tel. +49 5934 701-0 FRANCE Röchling Permali Composites S.A.S. 8, rue André Fruchard B.P.12, Maxéville 54527 LAXOU Cedex / France [email protected] www.permali.com Tel. +33 383 34 24 24

DENMARK Röchling Meta-Plast A/S Tøjstrupvej 31, 8961 Allingåbro [email protected] www.meta-plast.dk Tel. +45 8648 1711 RUSSIA Röchling Engineering Plastics (Russia) Ltd. Tambovskaya 12–43 192007 St. Petersburg [email protected] www.roechling-plastics.ru Tel. +7 812 320 9280

GERMANY Röchling Sustaplast SE & Co. KG Sustaplast-Str. 1, 56112 Lahnstein [email protected] www.roechling.com Tel. +49 2621 693-0

ITALY Röchling Machined Plastics Italia s.r.l Via Morena 66, 28024 Gozzano [email protected] Tel. +39 0322 95421

Röchling Sustaplast SE & Co. KG Lahnstr. 22, 56412 Nentershausen [email protected] www.roechling.com Tel. +49 6485 889-0

SPAIN Röchling Plásticos Técnos S.A.U. Ctra. Villena, s/n. - Apartado 34, 46880 Bocairent [email protected] www.roechling-plastics.es Tel. +34 962 350165

For further information please contact:

[email protected]

NORTH AMERICA

SOUTH AMERICA

ASIA

USA Röchling Machined Plastics 161 Westec Drive 15666 Mount Pleasant/USA [email protected] www.roechling-plastics.us Tel. +1 724 696-5200

BRASIL Rochling Plásticos de Engenharia do Brasil Ltda Avenida Emílio Chechinatto, 4.195 A Bairro São Roque da Chave Itupeva - São Paulo 13295-000 www.roechling.com Tel. +55 11 4496 8420

INDIA Röchling Engineering Plastics (India) Pvt. Ltd. 701, 'A' Wing, Leo Building 24th Road, Khar West 400 052 Mumbai / India [email protected] www.roechling-india.com Tel. +91 22 4217-8787

Röchling Glastic Composites 4321 Glenridge Road 44121 Cleveland/USA [email protected] www.roechling-glastic.com Tel. +1 216 486-0100

CANADA

CHINA Roechling International (Shanghai) Co., Ltd. 26/F Shanghai Times Square Office Tower 93 Huai Hai Zhong Road 200021 Shanghai/P.R. China Tel. +86 21 5117 6360 Fax +86 21 5117 7963 [email protected] www.roechling.com grafikdesign.1507020

Röchling Engineering Plastics 21 Tideman Drive L9W 3K3 Orangeville Ontario, Canada www.roechling-plastics.ca Tel. +1 519 941-5300

SINGAPORE Roechling Engineering Plastics Pte Ltd No. 14 Tuas Avenue 8 639229 Singapore Tel. +65 6863 1877 www.roechling.com.sg

www.roechling.com